Manual de Transmision DP 50 PDF

POWERSHIFT TRANSMISSIONS
1-Speed Transmission
(GP40K, GP40KL, GP45K, DP40K, DP40KL, DP45K) ................ 5 – 1
Structures and Functions ......................................................................... 5 – 1
Transmission .......................................................................................... 5 – 1
Torque Converter Assembly
(GP40K, GP40KL, GP45K, DP40K, DP40KL, DP45K) ....................... 5 – 3
Torque Converter Drive Control ............................................................. 5 – 4
Control Valve ......................................................................................... 5 – 4
Powershift Transmission Hydraulic System Schematic 1-Speed ............ 5 – 5 5
Removal and Installation .......................................................................... 5 – 6
Torque Converter ...................................................................................... 5 – 7
Overview ................................................................................................ 5 – 7
Inspection and Repair ............................................................................ 5 – 8
Transmission ............................................................................................ 5 – 10
Disassembly .......................................................................................... 5 – 10
Reassembly ........................................................................................... 5 – 21
Control Valve ............................................................................................ 5 – 28
Disassembly .......................................................................................... 5 – 28
Reassembly ........................................................................................... 5 – 30
Adjustment ............................................................................................... 5 – 31
Oil Pressure Measurement .................................................................... 5 – 31
Inching Valve Test .................................................................................. 5 – 32
Stall Speed Measurement ...................................................................... 5 – 32
10 m (33 ft) Starting Acceleration Test ................................................... 5 – 33
Inching Pedal Adjustment ...................................................................... 5 – 34
Automatic 2-Speed Transmission (GP50K, DP50K) ...................... 5 – 37
Structures and Functions ......................................................................... 5 – 37
Transmission .......................................................................................... 5 – 37
Torque Converter Assembly (GP50K, DP50K) ....................................... 5 – 39
Torque Converter Drive Control ............................................................. 5 – 40
Control System ...................................................................................... 5 – 41
Control Valve ......................................................................................... 5 – 42
Selector Valve ........................................................................................ 5 – 42
Hydraulic Control (Forward 1st Speed) .................................................. 5 – 43
Powershift Transmission Hydraulic System Schematic 2-Speed ............ 5 – 44
Transmission ............................................................................................ 5 – 45
Disassembly .......................................................................................... 5 – 45
Reassembly ........................................................................................... 5 – 54
Selector Valve ........................................................................................... 5 – 61
Disassembly .......................................................................................... 5 – 61
Reassembly ........................................................................................... 5 – 62
Adjustment ............................................................................................... 5 – 62
Oil Pressure Measurement .................................................................... 5 – 62
Oil Pressure Test Tools .......................................................................... 5 – 63
Travel Speed Select Switch Test ............................................................ 5 – 63
Troubleshooting ...................................................................................... 5 – 64
Service Data ............................................................................................. 5 – 68
1-Speed Transmission (GP40K, GP40KL, GP45K, DP40K, DP40KL, DP45K)
Structures and Functions

Transmission
4
b
(25)
3
a
(25)
2
5
c
(32) 9
F R
6
e
(40) 1
d
(37)
f
(17)
8
g 2nd
shaft
(GP:53)
(DP:55) 1st shaft
3rd
shaft
4th shaft
Indicated in ( ) are numbers of gear teeth.

209980
1 Flexible plate 6 Clutch shaft (1st shaft)

2 Torque converter assembly 7 Countershaft (3rd shaft)
3 Oil pump assembly 8 Output shaft (4th shaft)
4 Control valve 9 Turbine shaft (1st shaft)
5 Countershaft (2nd shaft)
5-1
The M15 transmission for the models shown at the right

Truck Model GP40K, GP40KL, GP45K,
has one forward and one reverse gears. The forward-
Item DP40K, DP40KL, DP45K
reverse changeover is accomplished by the powershift
mechanism that uses hydraulically-operated multi-plate Model M15
clutches.
Torque converter Three-element, single-stage,
type two-phase type
Shift positions Power path
F (forward) ce ➞ fg ➞ h
R (reverse) db ➞ ae ➞ fg ➞ h
Transmission reduction ratio
40 55
F (forward) × = 4.044
32 17
DP
29 40 55
R (reverse) × × = 4.057
37 25 17
40 53
F (forward) × = 3.897
32 17
GP
29 40 53
R (reverse) × × = 3.910
37 25 17
5-2
Torque Converter Assembly (GP40K, GP40KL, GP45K, DP40K, DP40KL, DP45K)
12
4
3
1
2
16
9
8
16
10
13
15 14
209981
1 Turbine runner 9 Thrust washer

2 Stator assembly 10 Thrust washer
3 Flexible plate 11 Spring cap
4 Pump impeller 12 Drive cover
5 Pump boss 13 Pilot boss
6 Roller 14 Ball bearing
7 Spring 15 Ball bearing
8 Hub 16 Thrust bearing
5-3
Torque Converter Drive Control
N
8
F
1
2
9
3
6
5 208459
1 Forward-reverse shift lever 4 Solenoid valve (forward) 7 Clutch lever

2 Bracket 5 Solenoid valve (reverse) 8 Cable
3 Control valve 6 Clutch valve plunger 9 Clutch pedal
Control Valve
1
Section A – A
A A
2
Section B – B
B B
3 4
C C
Section C – C
5
206593
1 Accumulator valve 3 Clutch valve plunger 5 Directional spool

2 Regulator valve 4 Clutch valve
5-4
Torque converter
Oil cooler
Torque converter Torque converter
outlet pressure inlet pressure
PD
PL
R
Accumulator valve
Lubricating
circuit PI
(Valve top surface with M stamp)

Main regulator valve
PM
Clutch (inching) valve
5-5
Hydraulic pump PC
47 liter (12.4 U.S. gal)/ (Valve top surface with
min at 2450 rpm D stamp)
FR filter
Suction strainer
Powershift Transmission Hydraulic System Schematic 1-Speed
Last chance
filter
Solenoid valve
Unit: MPa (kgf/cm2) [psi] Solenoid valve
F R
PM Main pressure 0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8] P2 F↔R
PC Clutch pressure 0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8]
Directional valve
PI Torque converter (Valve top surface)
inlet pressure 0.10 to 0.49 (1.0 to 5.0) [14.2 to 71.1]
PL Lube oil pressure 0.05 to 0.29 (0.5 to 3.0) [7.11 to 42.7]
All tests run At 1600 ± 100 engine rpm 206594
Removal and Installation Unit: mm (in.)
Removal Truck Model GP40K thru GP45K

Item DP40K thru DP45K
(1) Drain coolant and remove the radiator.
(2) Drain gear oil from the front axle housing. Distance between end
face of transmission case
(3) Remove the front axle shafts. 42 (1.7)
and mating face of
(4) Dismount the engine, transmission and differential flexible plate
as an assembled unit from the truck.
(5) Unscrew the flexible plate mounting bolts through (2) Tighten the flexible plate mounting bolts through
the access hole in the coupling case. the access hole in the coupling case.
(6) Separate the transmission from the engine. At this NOTE

time, support the engine with stands and sling the
transmission with a hoist. Tighten the bolts evenly in a diagonal sequence.
NOTE (3) Sling the engine, transmission and differential as an

For removal of the engine and transmission as an assembled unit with a hoist and install this
assembled unit, refer to the topics, “Removal and assembled unit to the front axle housing.
Installation” in the “GROUP 4 POWER TRAIN.” (4) Fill the front axle housing with gear oil to the
specified level. Fill the transmission and torque
Unit: kg (lb) converter with automatic transmission fluid to the
specified level. Fill the engine with antifreeze
Truck Model GP40K thru GP45K coolant.
NOTE
Weight of transmission
310 (682)
and differential assembly For installation of the engine and transmission as
an assembled unit, refer to the topics, “Removal
and Installation” in the “GROUP 4 POWER
TRAIN.”
Installation
(1) Couple the transmission to the engine. Install the
torque converter to the transmission case so that the
distance between the end face of coupling case and
the mating face of flexible plate should be 5 mm
(0.20 in.). Make sure the clearance between the
flywheel and flexible plate is approximately 2 mm
(0.08 in.) when the transmission is coupled to the
engine. If the clearance is zero, it is an indication
that the torque converter is improperly coupled to
the pump gear or splines; re-couple the
transmission to the engine correctly.
5-6
Torque Converter
Overview
209982
Sequence
1 Bolts, Plain washers
2 Flexible plate
3 Converter-assembly
Suggestion for Removal

The torque converter assembly has no drain plug and
cannot be drained completely. Drain the converter by
facing the pump boss side down.
5-7
Inspection and Repair
Pump impeller
(1) Check for cracks.
Pump impera
(2) Check for wear of the face of pump boss in contact
Oil seal
with oil seal.
O-ring
Pump boss
209983
Pilot boss
Check the surface in contact with the pilot bearing for wear
or other defects.
A: Standard value B: Repair or service limit

Unit: mm (in.)
− 0.007 − 0.00028
Diameter of shank in A 20 − 0.020 (0.78 − 0.00079 )
contact with pilot 1
bearing 1 B 19.95 (0.785)
209985
5-8
Flexible plate
(1) After installing flexible plate, measure the face runout
of the plate with a dial gauge. Replace the plate if the
runout exceeds the service limit.
Unit: mm (in.)
A 0.2 (0.008)
Face runout of flexible
plate
B 0.5 (0.020)
(2) With the flexible plate installed in position on the

transmission, make sure that the distance between the
transmission case end and the plate mounting surface is
42mm (1.7 in.). (GP40K, GP40KL, GP45K, DP40K,
DP40KL, DP45K)
42 mm
(1.7 in.)
209978
NOTE
After installing the flexible plate, fasten the plate to the
transmission case with wire.
209987
(GP40K, GP40KL, GP45K, DP40K,

DP40KL,DP45K)
5-9
Transmission
Disassembly
Control Valve and Strainer
Sequence
3 1 Drain plug, Washer
2 Torque converter thermo unit
3 Control valve
4 4 Subplate, Gasket
5 Strainer Hose
6 Strainer assembly, Gasket
5
2
5
5
209988
5-10
Pump Body Assembly
5
4
208469
Sequence
1 Pump body, Oil seal, Bushing 4 Valve, Spring, Washer, Snap ring
2 Internal gear, Drive gear, O-ring 5 Gasket
3 Stator shaft, Cap, Dowel pin 6 Turbine shaft, Seal ring, Snap ring
NOTE
It is not necessary to remove the cap and dowel pin from the stator shaft or the bushing and oil seal from the pump
body unless they are defective.
Suggestion for Disassembly
Removing pump body assembly Jack bolt
Unscrew all bolts securing the pump body assembly, and

remove the assembly with the jack bolt holes in the stator
shaft.
Special tool needed
Jack bolt 67284 - 15400

202888
5-11
Countershaft (2nd shaft)
3
1
6
2
7
5
1
4
208470
Sequence
1 Snap ring 5 Countergear, Spacer
2 Rear cover, O-ring 6 Countergear
3 Countershaft 7 Ball bearing
4 Ball bearing
Removing bearings
Remove snap ring 1 from its groove in advance. Screw a
sliding hammer into the tapped hole in shaft 3, pull off the
shaft, and remove bearings 4 from the transmission case.
5-12
Countershaft (3rd shaft)
202890
Sequence
1 Snap ring 4 Ball bearing 7 Roller bearing (inner)
2 Rear cover, O-ring 5 Countergear
3 Countershaft 6 Countergear
Removing ball bearing

With snap ring 1 removed from its groove, draw out
countershaft 3 using a sliding hammer attached to the
threaded end of the shaft, then remove ball bearing 4 from
the transmission case.
Output Shaft (4th shaft)

5
4
1
6
87
10
3
9
11
12 208471
Sequence
1 Output cover 5 Ball bearing 9 Bearing case
2 Output shaft subassembly 6 Snap ring 10 Oil seal
3 Shims 7 Nut 11 Taper roller bearing
4 Output gear 8 Oil seal race, O-ring 12 Bevel pinion
NOTE
Output shaft subassembly 2 consists of parts 6 to 12.
5-13
1. Removing output shaft

Jack bolt hole
Use the jack bolt holes (M12 × 1.25) in the bearing case to
draw out the output shaft assembly. When drawing out the
assembly, give pushes to the drive gear by applying the end
of a copper rod inserted through the countershaft (3rd shaft)
hole and tapping the rod with a hammer as the gear
interferes with the clutch drums on the turbine shaft
(transmission 1st shaft).
208472
2. Disassembling output shaft subassembly

The output shaft subassembly does not usually need to be
disassembled. If it must be disassembled, remove the
bearing using a press. Take care not to lose the inside
shims.
200091
5-14
Forward-reverse Clutch Shaft
20
8
6
7 25
5 26
4 27
3 28 29
2 29
1 30
23
1
16
15 24
14 9
22 10
21 19 12
16 11
13
17
18
19
207589
Sequence
1 Servo case, O-ring 12 Needle roller bearing 21 Retainer
2 O-ring 13 Thrust washer 22 Spring
3 Seal ring 14 Snap ring 23 Clutch piston, Ball, Screw
4 Ball bearing 15 Pressure plate 24 Seal ring
5 Thrust washer 16 Friction plates, 25 Snap ring
6 Forward gear Mating plates 26 Retainer
7 Needle roller bearing 17 Snap ring 27 Spring
8 Thrust washer 18 Pressure plate 28 Clutch piston, Ball, Screw
9 Ball bearing 19 Friction plates, 29 Seal ring
10 Thrust washer Mating plates 30 Clutch shaft
11 Reverse gear 20 Snap ring
NOTE
It is not necessary to remove the balls and screws from
the clutch piston, the screw from the clutch shaft, or
the steel ball from the servo case.
5-15
Disassembling clutch drum

A
Using special tool A or a press, compress return springs 22
and 27, and remove snap rings 20 and 25.
Special tool needed
Piston tool A 92267 - 00300
207504A
1. Oil pump
(1) Install the internal gear and drive gear in the pump
body, and measure top clearance 2.
(2) Using a dial gauge, measure side clearance 1 between
the gears and pump case.
(3) Measure clearance 3 of drive gear in pump boss
(notch).
(4) Check the relief valve for distortion or other defects.

Unit: mm (in.)
Truck Model GP40K thru GP45K
1
0.07 to 0.11
A 2
(0.0028 to 0.0043)
Side clearance 1 3
B 0.20 (0.0079)
0.3 to 0.33
A
(0.012 to 0.0130)
Top clearance 2
209989
B 0.45 (0.0177)
0.2 to 0.4
A
Drive gear clearance in (0.008 to 0.016)
pump boss notch 3
B 1.0 (0.039)
5-16
2. Pump boss

Unit: mm (in.)
0 0
Diameter of fitting A 70 − 0.046 (2.76 − 0.00181 )
surface in contact with
oil seal and bushing 1 B 69.90 (2.7520)
2 1
209990
70.06 to 70.10
A
Inside diameter of (2.7583 to 2.7598)
boss bushing 2
B 70.3 (2.768)
3. Stator shaft
(1) Check to make sure that bearings fit tight to the shaft.
(2) Check the splines for wear or damage.
(3) Check the oil passages for clogging.
4. Clutch pistons
(1) Shake each piston, making sure that the balls move
freely in the piston.
NOTE
Do not overhaul the pistons unless they are defective.
(2) Check the seal rings and their grooves for wear or
damage. Seal ring
207590
5. Friction plates and mating plates
(1) Check for sign of seizure, uneven contact, warpage or
excessive wear.
6. Clutch drums
(1) Check the mating plate sliding surfaces for wear or
damage.
(2) Check the clutch piston sliding surfaces for wear or
damage.
5-17
7. Clutch gears (forward and reverse)

(1) Check the gear and splines for wear or damage.
(2) Check the gear surface in contact with needle roller
bearing for wear or damage.

Unit: mm (in.)
Truck Model GP40K thru GP45K 7,8
2.3 ± 0.07
A
Thickness of mating (0.091 ± 0.0028)
plate 1
B 2.1 (0.083)
2.6 ± 0.1
A
Thickness of friction (0.102 ± 0.004) 6
plate 2 3
B 2.2 (0.087)
2 1
Backlash of friction 0.10 to 0.30
A 5
plate with gear 3 (0.0039 to 0.0118)
− 0.01 − 0.0004
A 4 − 0.03 (0.16 − 0.0012 )
Width of seal ring 4
B 3.5 (0.138)
+ 0.2 + 0.008
A 4 + 0.1 (0.16 + 0.004 ) 4 202900
Width of seal ring
groove in piston 5
B 4.5 (0.177)
Free length of clutch 63 (2.48)

A
spring 6 k = 39.1 (3.992) [223.3]
Spring constant:
k = N/mm (kgf/mm)
B 61 (2.40)
[lbf/in.]
2.5 ± 0.05
A
Width of clutch piston (0.098 ± 0.0020)
seal ring 7
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of clutch piston
seal ring groove 8
B 3.1 (0.122)
5-18
8. Turbine shaft and clutch shaft

Check the seal rings, shaft and case for wear or damage.

Unit: mm (in.)
2.5 ± 0.05
A
Width of turbine shaft (0.098 ± 0.0020)
seal ring 1
B 2.0 (0.079)
+ 0.2 + 0.008
Width of piston seal A 2.5 + 0.1 (0.098 + 0.004 )
ring groove in turbine
shaft 2 B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of A 35 0 (1.38 0 )
turbine shaft in contact
with seal ring 3 B 35.2 (1.386)
2.5 ± 0.05
A
Width of clutch shaft (0.098 ± 0.0020)
seal ring 4
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of clutch shaft
seal ring groove 5
B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of servo A 35 0 (1.38 0 )
case in contact with seal
ring 6 B 35.2 (1.386)
4, 5 1, 2
6 3
207591
5-19
9. Clutch shaft, countershafts, and output shaft

(2) Check oil passages for clogging.
10. Gears
Check each gear for worn teeth or splines.
11. Strainer assembly

Disassemble and clean. Replace the strainer if defective.
5-20
Reassembly
Forward-reverse Clutch Shaft (1st shaft)
203799
Sequence
1 Servo case, O-ring, Bolt, Spring washer, Washer
2 Forward-reverse clutch shaft assembly
Start by:
(1) Install the following parts to the transmission case in
advance:
• Ball bearing B for output shaft
• Outer race C of roller bearing for countershaft (3rd
shaft)
• Ball bearing D for countershaft (2nd shaft)
(2) Put output gear E in the transmission case.
Suggestions for Reassembly

(1) Install the forward-reverse clutch shaft as an assembly.
(2) Apply ATF oil to the inside surface of servo case and
the seal ring.
5-21
Clutch Shaft Assembly A
11 17 16 15 8 12 13 14 6
25 20
26
21
27 22
28
24 19
23 18
10 9 7 3 2 29 4 5
207592
Sequence
1 Clutch shaft 11 Snap ring 21 Thrust washer
2 Seal ring 12 Friction plates, Mating plates 22 Ball bearing
3 Clutch piston, Ball, Screw 13 Pressure plate 23 Thrust washer
4 Spring 14 Snap ring 24 Needle roller bearing
5 Retainer 15 Friction plates, Mating plates 25 Forward gear
6 Snap ring 16 Pressure plate 26 Thrust washer
7 Seal ring 17 Snap ring 27 Ball bearing
8 Clutch piston, Ball, Screw 18 Thrust washer 28 Seal ring
9 Spring 19 Needle roller bearing 29 Servo case, O-ring
10 Retainer 20 Reverse gear

A
(1) When inserting pistons 8, 3 into clutch drum 29, apply
ATF oil to their seal ring portions.
(2) Installing return spring
Using special tool A or an arbor press, compress
springs 9, 4 and install snap rings 11, 6.
Special tool needed
207504A
5-22
(3) Installing clutch plates

(a) Make sure that the combination and number of the
Friction plate
plates are correct. Install the plates while
applying ATF oil to them. When replacing the Mating plate
friction plates, replace the mating plates as a set.
207593
(b) Installing thrust washers

Make sure that the oil-groove side of thrust
washers 13, 8, 10, 5 faces the gear when
installed.
203800
(4) After assembling the clutch, apply air pressure of

approximately 69 kPa (0.7 kgf/cm2) [10 psi] to the oil
hole to make sure that the clutch parts move smoothly
without any sign of air leaks.
5-23
6 10 9 7 8 11 1213 14
202906
1
5
2
3
202905
Sequence
1 Ball bearing 4 Output shaft subassembly
2 Output gear 5 Output cover
3 Shims
Suggestion for Reassembly

Install the output shaft as an assembly 4. (2) Put LG2 grease on the oil seal.
(1) Reassembly sequence for output shaft (3) Tighten nut 13 to the specified torque, and stake it
in place to prevent loosening.
6 Output shaft
7 Taper roller bearing 353 to 392 N·m
Tightening torque for
8 O-ring (36 to 40 kgf·m)
nut 13
[260 to 289 lbf·ft]
9 Oil seal race
(Install 10 to 12 in an assembly unit.) Special tool needed
10 Bearing case
11 Oil seal Wrench 91868 - 00300
12 O-ring
13 Nut
14 Snap ring
5-24
3
2
7 4
6
5
202907
Sequence
1 Countershaft 5 Countergear
2 Snap ring 6 Ball bearing
3 Countergear 7 Rear cover, O-ring, Bolt, Spring washer
4 Roller bearing (inner)

Reassemble shaft 1, snap ring 2, gear 3 and roller bearing
inner race 4 outside the transmission case, without fitting
the snap ring in its groove, then put the shaft in the case,
and fit it to gear 5 inside the case.
2 1 3 4
202908
5-25
5 3 4 1
7
2
202909
Sequence
1 Ball bearing 5 Countergear
2 Counter shaft 6 Ball bearing
3 Snap ring 7 Cover, O-ring, Bolt, Spring washer
4 Snap ring, Countergear

Install shaft 2 to the transmission case with snap ring 3
temporarily fitted to the shaft.
3 2 4 5
202910
5-26
Pump Body Assembly
3 2
1
5
202911 202912
Sequence
1 Pump body, Oil seal, O-ring 4 Pump body assembly, Gasket, Bolt,
2 Internal gear, Drive gear Spring washer
3 Stator shaft, Dowel pin 5 Turbine shaft, Snap ring, Seal ring
Suggestions for Reassembly Control Valve and Strainer

(1) Install the pump body to the transmission case as an To reassemble, follow the reverse of disassembly
assembly. sequence. Replace the gaskets.
(2) Apply engine oil to the internal gear and drive gear
2 when installing them to pump body 1.
(3) Apply LG2 grease to the oil seal and bushing of
pump body 1.
Oil seal
(4) Upon reassembling, measure each gear backlash
with a dial gauge.
Unit: mm (in.)
Backlash of countergear 0.14 to 0.27
and output gear (0.0055 to 0.0106)
204833
0.14 to 0.26
Backlash of other gears
(0.0055 to 0.0102)
5-27
Control Valve
Disassembly
9
15 14
4 B
4
B
12 A
6 1
16
11
8 7 2
10 3
2
A
1 206613
Sequence
1 Solenoid valve, O-ring 9 Filter, O-ring
2 O-ring, Spring seat, Spring 10 Oil seal
3 Directional spool 11 Plug, Bearing roller, O-ring
4 Cover, O-ring, Bolt, Washer 12 Accumulator spring seat, Pin, O-ring
5 Accumulator piston, Accumulator spring 13 Filter
6 Regulator valve, Spring seat, O-ring, Main 14 Drain plug, Gasket
relief spring, Slug 15 Orifice screw, O-ring
7 Stopper pin, O-ring 16 Control valve body
8 Clutch valve plunger, Clutch valve spring,
Clutch valve, Return spring, slug
NOTE
Oil seal 10 does not need to be removed unless it is
found defective as a result of inspection.
5-28

(1) Check the valve housing for clogged oil passages.
(2) Check each plunger for traces of wear, damage or
seizure.
(3) Check the oil seals for damaged lips.
(4) Check the operating plunger steel ball and its seating
surface for abnormal condition.
(5) Check the orifice in the main regulator valve for
clogging. Also check the valve spring for fatigue,
weakness or damage. 200220

Unit: mm (in.)
Free length of main relief valve 75 (2.95)
A
inner spring 1 k = 2.11 (0.2154) [12.05] 7
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] B 72 (2.83) 6
1
Free length of main relief valve 50 (1.97) 2
A 3
outer spring 2 k = 0.838 (0.0855) [4.78]
Spring constant: 4
k = N/mm (kgf/mm) [lbf/in.] B 48 (1.89) 8 8
Free length of inching valve 39 (1.54)

A
spring 3 k = 2.13 (0.217) [12.1]
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] B 38 (1.50) 206614
Free length of inching valve 28 (1.10)

A
spring 4 k = 0.478 (0.0488) [2.73]
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] B 26.5 (1.04)
Free length of torque converter 32 (1.26)

A
inlet/outlet pressure regulating k = 4.56 (0.465) [26.0] 5
valve spring 5
Spring constant:
k = N/mm (kgf/mm) [lbf/in.] B 31 (1.22)
Free length of accumulator 91 (3.58)

A
valve outer spring 6 k = 7.30 (0.7447) [41.7]
Spring constant: 203001
Free length of accumulator 130 (5.12)

A
valve inner spring 7 k = 0.676 (0.0609) [3.40]
Spring constant:
Free length of directional spool 32.5 (1.28)

A
spring 8 k = 8.616 (0.8786) [49.2]
Spring constant:
5-29
Reassembly
Section A – A 1
12
4 11
A A
5 10
2 12
10
Section B – B
B B 8
6 12
7
9
C C
Section C – C
15 8 7 13 14 15
3
206593
Sequence
1 Control valve body 9 Stopper pin, O-ring
2 Orifice screw 10 Regulator valve, slug, Main relief spring,
3 Filter Spring seat, O-ring
4 Accumulator spring seat, O-ring, Pin 11 Accumulator piston, Accumulator spring
5 Plug, O-ring, Bearing roller 12 Cover, O-ring, Bolt, Washer
6 Oil seal 13 Directional spool
7 Filter, O-ring 14 Spring seat, Spring, O-ring
8 Clutch valve plunger, Clutch valve, 15 Solenoid valve, O-ring
Clutch valve spring, Return spring, Slug
Start by:
Thoroughly clean all the oil passages in the valve housing.
Make sure they are free from clogging before reassembling
the valve housing.
5-30
Adjustment
Oil Pressure Measurement
Torque converter
(1) Connect a pressure gauge (1961 kPa (20 kgf/cm2) inlet pressure
[284 psi]) to the pressure tap (M14 × 1.5 thread).
Special tools needed
Connector 91268 - 04400

*Hose 64309 - 17722 M
*Connector 64309 - 17731

*Gauge 64309 - 17713
Tools marked with an asterisk (*) are included in

the gauge kit 64309 - 17701. Main Clutch Lube oil
pressure pressure pressure
206615
(2) Start and run the engine at an idling speed, and
check that the oil level is correct in the transmission
case.
(3) Warm up until the torque converter oil temperature
gauge indicates the green zone.
(4) Run the engine at a speed between 1000 and 1500
rpm.
NOTE
Observe the engine tachometer reading.
Oil pressure test tools (reference)

Unit: kPa (kgf/cm2) [psi]
0.98 to 1.23 Torque
Main pressure Main converter
(10 to 12.5)
(engine at 1600 ± 100 rpm) Special
Tool number Remarks
pressure, inlet
[142 to 178] tool Clutch pressure,
pressure Lube oil
0.98 to 1.23 pressure
Clutch pressure
(10 to 12.5)
(engine at 1600 ± 100 rpm)
[142 to 178] Connector 91268 - 02300 M14 × 1.5 –
01.0 to 0.49 * R 1/8

Torque converter inlet pressure Connector 64309 - 17733
(1 to 5) thread
(engine at 1600 ± 100 rpm)
[14.5 to 71]
*
Hose 64309 - 17722
0.05 to 0.29
Lube oil pressure
(0.5 to 3) *
(engine at 1600 ± 100 rpm) Connector 64309 - 17731 For gauge
[7 to 42]
590 kPa
Gauge 64309 - 17714 (6 kgf/cm2)
[86 psi]
Tools marked with an asterisk (*) are included in the

gauge kit 64309 - 17701.
5-31
Inching Valve Test
Start by:
(1) Raise the front axle housing with a jack and place
wood blocks under the outer mast. Tilt the mast
forward to raise the front wheels.
(2) Block the rear wheels.
! CAUTION
Remember, the front wheels will rotate when the
clutch pressure is tested.
Procedure
(1) Set the inching pedal stroke to the specified value.
(2) Connect a pressure gauge to the clutch pressure tap
(M14 × 1.5). 980
(10)
kPa (kgf/cm2) [psi]

Use the same special tools in page 5-31.
Clutch pressure,
[142]
(3) Move the operating plunger to the forward position.
590
(4) Gradually pull out the inching valve plunger from its (6.0)
[86]
fully pushed position, and plot the oil pressure curve
relative to the plunger stroke. Make sure that the
pressure curve is identical with the curve shown. 0 5 10
(0.20) (0.39)
Inching valve stroke, mm (in.)
202914A
Stall Speed Measurement

(1) Run the engine at an idling speed, and check that the
oil level is correct in the transmission case.
(2) Warm up the torque converter oil.
(3) Block the front and rear wheels, and apply the parking
brake.
(4) Run the engine at an idling speed.
5-32
(5) Depress the brake pedal strongly by the left foot, move
the forward-reverse lever to the forward position, and
gradually depress the accelerator pedal all the way by
the right foot. Under this condition, observe the engine
tachometer reading.
Unit: rpm
Truck Model GP40K DP40K
thru thru
Item GP50K DP50K
Stall speed 2157 1954

(Tolerance: ± 100 rpm)
! CAUTION
Do not attempt to depress the inching pedal. Do
not continue “stall speed” run for more than 10
seconds. A failure to follow this precaution would
result in destruction of the torque converter.
(6) Similarly read the stall speed for reverse drive.
NOTE
(a) Any stall speed within ± 100 rpm of the
specification is satisfactory.
(b) If the engine or torque converter is changed, the
stall speed will vary since the stall speed is
determined by the combination of engine and
torque converter.
10 m (33 ft) Starting Acceleration Test

(1) Stand ready to start with the engine idling and the
forward-reverse lever in the neutral position.
(2) At a signal, shift into forward and, at the same time,
depress the accelerator pedal all the way.
(3) Measure the amount of time the truck elapses to travel
10 m (33 ft) with a stopwatch.
(4) Measure for reverse travel, too.
Travel time (no load) 5 seconds, maximum
5-33
Inching Pedal Adjustment
1. Adjusting brake
(1) Bleed air out of the brake lines from the reserve tank
through master cylinder to the wheel cylinders.
NOTE
For bleeding, refer to page 8-26 in the “GROUP 8
Clevis
BRAKE SYSTEM.”
Rod
(2) Screw the rod fully into the clevis on the brake pedal
side.
202814
(3) Screw the lock nut on the operating rod of booster.

Screw the operating rod into the rod until the remaining Rod Lock nut Operating rod
thread length measures 14 mm (0.55 in.) and tighten
the lock nut.
14 mm
(0.55 in.)
Boot
201815
(4) Adjust the brake pedal height A to 223 mm (8.8 in.) by

turning the operating rod, and tighten the lock nut on
the pedal side.
A Stopper bolt
(5) Decrease the brake pedal height A to 220 mm (8.7 in.)
by the stopper bolt (until the operating rod push the
booster slightly).
Lock nut
202817
5-34
(6) Adjust and confirm the brake shoe lining clearance.

Do not adjust this clearance by setting the push rod
length; the clearance is to be adjusted with the auto-
matic adjuster.
Unit: mm (in.)
Truck Model GP40K, GP40KL GP45K, GP50K
Item DP40K, DP40KL DP45K, DP50K
Clearance 0.30 to 0.40 0.40 to 0.60

between brake
lining and drum (0.012 to 0.016) (0.016 to 0.024)
2. Adjusting inching pedal

(1) Connect a pressure gauge to the clutch pressure tap.
Stopper bolt
220 mm
A Top of frame
NOTE (8.7 in.)
For the special tools to be used with the pressure

gauge, refer to page 5-31.
(2) Adjust the height A of inching pedal to 220 mm (8.7

in.) by the stopper bolt. Adjust the clearance between
202915
inching pedal and brake pedal B.
Unit: mm (in.)
Clearance between brake 0.1 to 0.5
pedal and inching pedal (0.004 to 0.020)
(3) Start the engine, and release the brake pedal. Depress
the inching pedal until the brakes start applying (that is, E
the pedal encounters resistance). Under this condition,
reposition the rod and ball joint so that inching valve B
plunger stroke D is 16 mm (0.63 in.) at 0 kgf/cm 2
pressure.
Unit: mm (in.)
202916
Truck Model GP40K, GP40KL GP45K, GP50K
Item DP40K, DP40KL DP45K, DP50K
Inching pedal 60 to 65 50 to 55
stroke at which
brakes start applying (1.85 to 3.03) (0.94 to 1.69)
5-35
(4) Release the inching pedal, and make sure that inching
valve plunger stroke C is 6 to 9.5 mm (0.24 to 0.37 in.)
at a pressure of 883 to 1079 kPa (9 to 11 kgf/cm2) [128
to 156 psi]. If the stroke is incorrect, readjust the brake
and brake pedal, and repeat the adjustment.
If the inching valve plunger stroke is more than 9.6 D
mm (0.38 in.), the lining to drum clearance is too
C
small.
If the inching valve plunger stroke is less than 5.9 mm
(0.23 in.), the lining to drum clearance is too large.
Unit: mm (in.) 981

(10)
[142]
Inching pedal height
A 220 (8.7) Clutch oil pressure,
(from frame to top of pedal pad) 588 kPa (kgf/cm2) [psi]
(6.0)
[85]
Clearance between inching 0.1 to 0.5
B
pedal and brake pedal (0.004 to 0.020) 10
(0.39)
5
(0.20)
0
Inching valve plunger stroke, mm (in.)

6 to 9.5 207686
C Inching valve plunger stroke
(0.24 to 0.37)
Inching valve plunger stroke at

D 16 (0.63)
which brakes start applying
Rod and ball joint length

E 228 (8.98)
(standard value)
5-36
Automatic 2-Speed Transmission (GP50K, DP50K)
Structures and Functions

Transmission
b c
(52) 4 (24)
a
(34)
6 2
g 1
(34)
3
e
(52)
8 h
d (24)
(36)
k
i
f (17)
(45)
9
11
5 4
10 j
(GP:51)
(DP:52)
1st shaft
209992
2nd shaft
3rd shaft
4th shaft
206617 Indicated in ( ) are numbers of gear teeth.
1 Flexible plate 7 Input shaft (1st shaft)

2 Torque converter assembly 8 Countershaft (3rd shaft)
3 Pump body assembly 9 Output shaft (4th shaft)
4 Control valve 10 Magnet strainer
5 Solenoid valve 11 Travel speed sensor
6 Countershaft (2nd shaft)
5-37
This transmission is forward two-speed and reverse two-

Truck Model
speed, hydraulic-operated, multiple-plate type powershift GP50K, DP50K
Item
transmission.
The torque converter for the two-speed transmission is the Model M15
same as that for the one-speed transmission.
Torque converter Three-element, single-stage,
type two-phase type
Shift positions Power path
F1 (forward 1st) hf ➞ ij ➞ k
F2 (forward 2nd) gd ➞ ij ➞ k
R1 (reverse 1st) eb ➞ cf ➞ ij ➞ k
R2 (reverse 2nd) eb ➞ ad ➞ ij ➞ k
Transmission reduction ratio
45 52
F1 (forward 1st) × = 5.735
24 17
36 52
F2 (forward 2nd) × = 3.239
34 17
DP
52 45 52
R1 (reverse 1st) × × = 5.735
52 24 17
52 36 52
R2 (reverse 2nd) × × = 3.239
52 34 17
45 51
F1 (forward 1st) × = 5.625
24 17
36 51
F2 (forward 2nd) × = 3.176
34 17
GP
52 45 51
R1 (reverse 1st) × × = 5.625
52 24 17
52 36 51
R2 (reverse 2nd) × × = 3.176
52 34 17
5-38
Torque Converter Assembly (GP50K, DP50K)
12
4
3
1
2
16
9
8
16
10
13
15 14
209981
1 Turbine runner 9 Thrust washer

2 Stator assembly 10 Thrust washer
3 Flexible plate 11 Spring cap
4 Pump impeller, O-ring 12 Drive cover
5 Pump boss 13 Pilot boss, O-ring
6 Roller 14 Ball bearing
7 Spring 15 Ball bearing
8 Hub 16 Thrust bearing
NOTE
The torque converter assembly for the two-speed
transmission is same as that for the one-speed
transmission (GP40K, GP40KL, GP45K, DP40K,
DP40KL, DP45K).
5-39
Torque Converter Drive Control
R 9
N
F
1
2
8 7
4
10
6 5 3
208485
1 Forward-reverse shift lever 6 Clutch valve plunger

2 Bracket 7 Selector valve
3 Control valve 8 Clutch lever
4 Solenoid valve (forward) 9 Cable
5 Solenoid valve (reverse) 10 Clutch pedal
NOTE
This torque converter drive control is a combination of
the torque converter drive control for the 1-speed
transmission and the mechanism that enables the
automatic 2-speed transmission to make gearshifts
automatically.
5-40
Control System
New
Travel speed select switch

Former
1st speed
Solenoid clutch
Output ECU
gear valve 2nd speed
clutch
Travel speed sensor Electrical signal
Hydraulic pressure signal
0.5 mm Transmission case
(0.02 in.)
(0.02 in.)
Travel speed Travel speed

select switch select switch
ECU
ECU
Power
Power source
source
Solenoid
valve
Solenoid
valve
FORMER
NEW
206761
Travel speed sensor
212043 Travel speed sensor
Locations of control devices
The automatic 2-speed transmission consists of an F2-

R2 powershift transmission and a control system Select switch position Travel speed
comprising a travel speed sensor, an electronic control
unit (ECU) and a solenoid valve. 0 to 8 km/h
1st speed
(0 to 5.0 mph)
Automatic
2-speeds
1st speed or automatic 2-speeds can be selected by 9 to 24.5 km/h
2nd speed
means of the travel speed select switch. (5.6 to 15.2 mph)
0 to 14 km/h
1st speed
(0 to 8.7 mph)
5-41
Control Valve
1
Section A – A
A A
2
Section B – B
B B
3 4
C C
Section C – C
5 206593
1 Accumulator valve 4 Clutch valve

2 Regulator valve 5 Directional spool
3 Clutch valve plunger
Selector Valve
4 3 1 2 6 5
206619
1 Solenoid body 4 Cover

2 Solenoid valve 5 Cover
3 Spring 6 Solenoid valve (electromagnetic valve)
5-42
Hydraulic Control (Forward 1st Speed)
Forward 1st speed [lower tan 9 km/h (5.6 mph)]
• Turning the starter switch ON energized the

solenoid valve (normally-closed) to open,
shifting the gear to 1st.
203804
5-43
5-44
Powershift Transmission Hydraulic System Schematic 2-Speed
Unit: MPa (kgf/cm2) [psi]

PM Main pressure 0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8]
PC Clutch pressure 0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8]
PI Torque converter
0.10 to 0.49 (1.0 to 5.0) [14.2 to 71.1]
inlet pressure
PL Lube oil pressure 0.05 to 0.29 (0.5 to 3.0) [7.11 to 42.7]
All tests run At 1600 ± 100 engine rpm 206620
Transmission
Disassembly
Control Valve and Side Cover
209997
Sequence
1 Drain plug, Washer 5 Subplate, O-ring, Gasket
2 Torque converter thermo unit 6 Generator cover, Sensor
3 Solenoid valve 7 Strainer assembly, O-ring
4 Control valve 8 Side cover, Gasket
5-45
208488
Sequence
1 Output cover 3 Taper roller bearing, Race, Nut, Snap ring
2 Output shaft subassembly 4 Output gear
Suggestions for Disassembly

(1) Removing output shaft
Use the special tool A to remove the output shaft
subassembly. The output gear will interfere with the
gear of countershaft (3rd shaft). This makes it
necessary to remove the shaft while tapping the output
gear with a copper hammer through side cover hole.
Special tool needed A
202892
Output shaft puller A 91868 - 02100
(The same tool as that used for 1-speed transmission)
(2) Disassembling output shaft

Usually, it is not necessary to disassemble the output
shaft. When it has to be disassembled, use a press to
remove the bearing. Take care not to lose the shims
during disassembly.
200091
5-46
Pump Body
208489
Sequence
1 Pump body, Roller bearing (outer race), 2 Stator shaft, Valve, Spring washer,
Bushing, Oil seal, Gasket, O-ring Snap ring, Steel ball
3 Drive gear, Driven gear

(1) Removing pump body assembly
Unscrew all body mounting bolts and, using the jack
bolts, remove the assembly.
Special tool needed
Jack bolt 67284 - 15400
(2) Do not remove the steel ball and plug fitted to the
pump body, or the bushing, oil seal, steel ball and cap,
fitted to the stator shaft, unless they are defective. 202923
5-47
7
8
1
2
3
4
5
208490
Sequence
1 Cover, O-ring 6 Spacer
2 Roller bearing (inner race) 7 Gear (forward 2nd speed countergear)
3 Collar 8 Ball bearing
4 Output gear (countergear) 9 Countershaft
5 Gear (forward 1st speed countergear)

(1) Removing roller bearing
To remove roller bearing 2, attach a gear puller to
output gear 4, and remove the bearing, gear and collar
3 as a set.
(2) Removing countershaft
Attach a sliding hammer to countershaft 9, and remove
the shaft complete with ball bearing 8.
5-48
Input Shaft (1st shaft)
13 14
6 16
15
5
4 17
2 13
3
15
1
16
12 2
7
8
9
11
10
14
13
12
12
11
12
207595
A: Input shaft assembly (consisting of parts 2 thru 17)
Sequence
1 Servo case, O-ring 10 Thrust washer
2 Seal ring 11 Snap ring, Pressure plate
3 Ball bearing 12 Friction plates, Mating plates
4 Thrust washer 13 Snap ring, Retainer
5 Gear (forward 2nd speed drive), Needle roller 14 Clutch spring
bearing 15 Clutch piston, Ball, Screw, Seal ring
6 Thrust washer 16 Seal ring
7 Ball bearing 17 Input shaft
8 Thrust washer
9 Gear (forward 1st speed drive), Needle roller
bearing
NOTE
Do not remove the steel ball fitted to the servo case or
the screw fitted to the input shaft.
5-49

(1) Removing input shaft ball bearing
Use the special tools to remove ball bearing 3 from the 1
input shaft.
Special tools needed
Ref.
Tool name Part No.
No.
2 3
4
1 Puller 91268 - 13810
2 Plate 91268 - 13820 207503
3 Bolt F1035 - 10020
T24
4 Gear puller
(BANZAI make)
(2) Disassembling input shaft

A
Using the special tool or a press, compress clutch
spring 14, and remove snap ring 13.
Special tool needed
207504A
(3) Clutch piston

Shake each piston 15, making sure that the balls move
freely in the piston.
5-50
17
5
4
3 15
2
1 16
12
11
11
14 2
13 3
6 7
12 8
12
9
10
13
14
16
15
12
207596
B: Countershaft assembly (consisting of parts 2 thru 17)

Sequence
1 Servo case, O-ring 10 Thrust washer
2 Seal ring 11 Snap ring, Pressure plate
3 Ball bearing 12 Friction plates, Mating plates
4 Thrust washer 13 Snap ring, Retainer
5 Gear (reverse 2nd speed drive), Needle roller 14 Clutch spring
bearing 15 Clutch piston, Seal ring, Steel ball, Screw
7 Snap ring 17 Countershaft
8 Thrust washer
9 Gear (reverse 1st speed drive), Needle roller
bearing

For disassembly of the countershaft and clutch piston, refer
to the previous paragraph “Disassembly of Input Shaft.”
5-51

For the following parts, refer to the section “1-speed
Transmission”:
(1) Oil pump
(2) Pump boss
(3) Stator shaft
(4) Clutch pistons
(5) Friction plates and mating plates
(6) Clutch drums
(7) Clutch gears
(8) Input shaft, countershafts, output shaft
(9) Gears
(10) Strainer assembly
Input shaft, servo case and seal rings

Check the contact surfaces of each part for wear or damage.

Unit: mm (in.)
Truck Model GP50K
Item DP50K
2.5 ± 0.05
A
Width of input shaft (0.098 ± 0.0020)
seal ring 1
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of seal ring
groove in input shaft 2
B 3.0 (0.118)
+ 0.025 + 0.00098
stator shaft in contact
2.5 ± 0.05
A
Width of input shaft (0.098 ± 0.0020)
seal ring 4
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of input shaft
seal ring groove 5
B 3.0 (0.118)
+ 0.025 + 0.00098
clutch shaft in contact
5-52
NOTE
The dimensions of the seal rings and their grooves for
the countershaft are identical with those for the input
shaft.
1,2
4,5 6 3
207597
5-53
Reassembly
Ball Bearing and Oil Seals
❋2
202930
Sequence
1 Ball bearing
❋2 Oil seals
NOTE
Removal of the output shaft will leave the ball bearing
and oil seals in the transmission case. Remove them
for replacement only when they are found defective.

To install the oil seals, use the special tool to press them Transmission case Oil seals
squarely. Special tool
Special tool needed
Installer 91868 - 02200
203479
5-54
Countershaft (2nd shaft) and Input Shaft (1st shaft)
17
B
5
17
15
A
16 6
14 1312 7 3 2 8 9 10 11 16 1
207598
Start by:
(1) Reassemble the countershaft subassembly B.
(2) Reassemble the input shaft subassembly A.
Sequence for input shaft subassembly

1 Input shaft 10 Thrust washer
2 Seal ring 11 Ball bearing
3 Clutch piston, Ball, Screw, Seal ring 12 Thrust washer
4 Clutch spring 13 Gear (forward 2nd speed drive), Needle roller
5 Snap ring, Retainer bearing
6 Friction plates, Mating plates 14 Thrust washer
7 Snap ring, Pressure plate 15 Ball bearing
9 Gear (forward 1st speed drive), Needle roller 17 Servo case, O-ring
bearing
NOTE
Reassembly sequence and suggestion for reassembly
for the countershaft are the same as those for the input
shaft.
Sequence for countershaft

1 ➞ B Countershaft subassembly ➞ A Input shaft subassembly
5-55

A
(1) Installing clutch spring
Using the special tool A or an arbor press, compress
clutch spring 4, and fit snap ring 5.
Special tool needed
(2) When inserting clutch piston 3 into the drum of the

countershaft 1 or input shaft 1, apply ATF oil to the 207504A
seal rings.
(3) Installing clutch plate
Make sure that the combination and number of the
plates are correct. Reassemble the plates while
applying ATF oil to each plate. When replacing the
friction plates, replace the mating plates as a set.
(4) After reassembling, apply air pressure of
approximately 69 kPa (0.7 kgf/cm2) [10 psi] to the oil
hole to make sure that the clutch parts move smoothly
without any sign of air leaks.
5-56
9
5
6
2
3
8
7
4
206764
Sequence
1 Countershaft 6 Output gear (countergear)
2 Ball bearing 7 Collar
3 Gear (forward 2nd speed countergear) 8 Roller bearing (inner race)
4 Spacer (Temporary reassembly) 9 Cover, O-ring
5 Gear (forward 1st speed countergear)

When placing gear (forward 2nd speed countergear) 3 in
the transmission case, slightly pull out the input shaft
subassembly and countershaft subassembly (2nd shaft) to
prevent interference of these shafts with the gear.
5-57
Pump Body
206765
Sequence
1 Pump body, Roller bearing (outer race), 2 Drive gear, Driven gear
Bushing, Oil seal, Gasket, O-ring 3 Stator shaft, Valve, Spring washer,
Snap ring, Steel ball

(1) Install the pump body to the transmission case as an
assembly.
(2) Apply ATF oil to the internal gear and drive gear when
installing them to the pump body.
(3) Put LG2 grease on the oil seal and bushing of the pump
body 1.
5-58
Output Shaft
206766
Sequence
1 Output gear 3 Output cover
2 Output shaft subassembly

(1) Install the output shaft as subassembly 2.
(2) Shim adjustment of output shaft
Centerline of axle
Before installing the bearing, determine the required

c
thickness of shims by referring "a" and "b" to this
formula:
a
Thickness of shims (c) = 1.7 + −b ±b
100
Where a: machining error indicated in a unit of 1/100 ± a
mm (0.0004 in.) on differential carrier by 100 202825
punching
Unit: mm (in.)
b: machining error of bevel pinion
Backlash of 1st speed gear 0.14 to 0.23
(3) Apply LG2 grease to the oil seals fitted to the and forward 2nd speed gear (0.0055 to 0.0091)
transmission case.
Backlash of forward gear 0.14 to 0.24
(4) Upon reassembling, measure each gear backlash with a and reverse gear (0.0055 to 0.0094)
dial gauge.
Backlash of countergear 0.14 to 0.25
and output gear (0.0055 to 0.0098)
5-59
Torque Converter
Stator shaft
Turbine shaft
Torque converter assembly
Pump boss
209992
Reassembly
Install the torque converter assembly to the transmission.

(1) Align the splines of the transmission-side stator shaft,
the turbine shaft and the pump boss completely. The
distance between the end face of the housing and the
mating face of the flexible plate is 4 to 6 mm (0.157 to
0.236 in.) if the torque converter is properly placed in
the transmission. Apply ATF oil to the sliding surfaces
of the oil seal and the bushing.
(2) The torque converter is only inserted and not secured.
Attach the flexible plate to the housing with a wire.
Control Valve and Side Cover

42 mm
To reassemble, follow the reverse sequence of disassembly. (1.7 in.)
209978
Replace the gaskets and O-rings with new ones.
5-60
Selector Valve
Disassembly
202936
Sequence
1 Cover, Gasket 4 Spring
2 Solenoid, O-ring 5 Valve
3 Cover, O-ring 6 Body, Gasket

(1) Check the valve body for clogged oil passages.
(2) Check the valve for wear, damage or seizure.
(3) Check the spring for damage or fatigue.
A: Standard value
Unit: mm (in.)
Free length of solenoid
valve spring
87.5 (3.4)
Spring constant: A
k = 3.883 (0.397) [121]
k = N/mm (kgf/mm)
[lbf/in.]
5-61
Reassembly
1 3 2 6 5
202919
Sequence
1 Body, Gasket 4 Cover, O-ring
2 Valve 5 Solenoid, O-ring
3 Spring 6 Cover, Gasket
Start by:
Clean the valve body thoroughly, making sure that all oil
passages are free from clogging.
Adjustment
Oil Pressure Measurement
Torque converter
The taps differ from those for the 1-speed transmission. inlet pressure
For the test method and oil pressure specifications, refer to
the section “1-speed Transmission.”
Unit: MPa (kgf/cm2) [psi]

0.98 to 1.23
M
Main pressure (10.2 to 12.5)
[142.2 to 177.8]
0.98 to 1.23
Clutch pressure (10.2 to 12.5)
[142.2 to 177.8]
Main Clutch Lube oil
0.10 to 0.49 pressure pressure pressure
Torque converter inlet
(1.0 to 5.0)
pressure 206615
[14.2 to 71.1]
Location of pressure taps
0.05 to 0.29
Lube oil pressure (0.5 to 3.0)
[7.11 to 42.7]
All tests run At 1600 ± 100 engine rpm
5-62
Oil Pressure Test Tools
Torque converter
Main pressure,
Tool name Part number Remarks inlet pressure,
Clutch pressure
Lube oil pressure
Connector 91268 - 04400 M14 × 1.5 thread –

*
Connector 64309 - 17733 R 1/8 thread –
Connector 91268 - 02300 M14 × 1.5 thread – –
588 kPa
*
Gauge 64309 - 17714 (6 kgf/cm2) –
[85 psi]
1961 kPa
*
Gauge 64309 - 17713 (20 kgf/cm2) –
[284 psi]
*
Hose 64309 - 17722
Connector 64309 - 17731 For gauge

Tools marked with an asterisk (*) are included in the gauge kit 64309 - 17701.
For the following four items, refer to the section “1-speed

Transmission.”
• Oil pressure
• Stall speed
• 10 m (33 ft) starting acceleration
• Inching pedal adjustment
Travel Speed Select Switch Test

Move the select switch mounted on the side face of console
box to each position, and make sure that the transmission
functions properly.
In the “1ST SPEED” position, the truck runs at a maximum Former 206632
speed of 14 km/hr (8.7 mph) and a greater torque is

available at the drive axle.
In the “AUTO” position, the transmission automatically

shifts from 1st to 2nd range when the travel speed reaches 9
km/hr (5.6 mph) to allow the truck to run at a maximum
speed of 24.5 km/hr (15.2 mph).
New 212043
5-63
Troubleshooting
Engine lacks power Tune up engine.

Engine
Poor performance of engine Tune up engine.
Oil level too low Refill.

Air being sucked in on suction side Replace gasket and
retighten.
Faulty action of spool in main relief valve Repair or replace.
Weakened spring in main relief valve Replace.
Torque
Worn gears in oil pump, resulting in Overhaul and check or
converter
reduced capacity replace defective parts.
Magnet strainer clogged Replace.
Seal rings or O-rings worn Replace.
Stator freewheel seized Replace stator assembly,
hub, roller.
Blades of running members damaged or Repair or replace.
Not enough rubbing Replace bearing.
output power
Air being sucked in on suction side Retighten or replace.

Outlet pressure too low to suppress internal Readjust.
foaming
Water in oil Replace oil.
Pedal linkage maladjusted (brake shift and Readjust.
Transmission
forward reverse)
Main pressure too low, resulting in slipping Readjust.
clutches
Seal rings or O-rings worn Replace.
Clutch piston damaged Replace.
Friction plate seized or dragging Replace.
Road wheels High mechanical resistance in road wheels Check and adjust brake
system.
Flexible plate broken Replace.

Not enough oil Refill.
No power Torque
Oil pump drive defective Replace.
flow converter
Turbine shaft broken Replace.
Main pressure too low Check pump gears for
wear or replace.
5-64

Inching pedal link maladjusted Readjust.
Seal ring worn in servo case Replace.
O-rings on input shaft worn Replace.
Plug on input shaft loose or slipped off, Repair.
resulting in oil leaks
No power Clutch seized Replace.
Transmission
flow
Shafts broken Replace.
Clutch drum, particularly snap ring groove, Replace.
defective
Snap ring fitted to clutch drum broken Replace.
Oil way for supplying oil pressure to clutch Clean or replace.
piston clogged
Shaft splines worn Replace shafts.
Power train Broken parts in reduction differential or Repair or replace.
front axle
Flexible plate broken Replace.

Bearings damaged Replace.
Torque Rubbing blades of running member Replace.
converter Bolts loose Retighten or replace.
Splines worn Replace.
Oil pump noisy Repair or replace.
Clutch seized and dragging Replace clutch plate.
Bearings worn or seized Replace.
Transmission Gears broken Replace.
Bolts loose Retighten or replace.
Splines worn Replace.
Abnormal Oil strainer clogged Clean.
noise Main relief valve defective Wash or replace.
Restriction in oil pipe Replace.
Loud noise
Oil too viscous in cold weather Replace oil.
Instruments out of order Replace.
Wrong kind of oil used Replace oil.
Oil strainer clogged Clean or replace.
Oil pump defective Replace.
Excessive oil leaks
• Main relief valve spring broken or Replace.
Low noise weakened
• Main relief valve spool defective Repair or replace.
Air being sucked in Retighten or replace
packing.
5-65
Leaking oil seals Check lips and sliding

surfaces for wear.
Replace seals.
Leaking joint of case Retighten or replace
packing.
Leaking pipe connection or joint Repair or replace pipe,
gasket and O-rings.
Leaking drain plug Retighten and replace
Oil leaks gasket.
Cracks or blowholes in case Replace.
Oil blowing out of transmission case
• Water in oil Replace oil.
• Air being sucked in suction side Replace packing and
retighten.
• Oil leaks from air breather Repair.
Oil level too high Lower oil level.
Oil level too high or too low Keep correct oil level.
Oil strainer clogged Clean or replace.
Rubbing blades of running members Repair or replace.
Stator freewheel defective Replace stator assembly.
Torque
gasket.
converter
Water in oil Replace oil.
Restriction in oil pipe (resulting in Repair or replace.
reduced circulation flow)
Bearings worn or seized Repair or replace.
Oil temperature
Instruments out of order Replace.
is too high
Clutches dragging Replace clutch plate.
Transmission Bearings worn or seized Repair or replace.
Control linkage defective Repair or replace.
Truck not operated properly Urge user to drive truck
Others properly.
Others
• Cooling fan belt damaged Replace.
• Oil cooler clogged Clean or replace.
• Brakes grabbing Check and readjust.
Main regulator valve defective Repair or replace valve

assembly.
Main pressure is too high Oil viscosity too high because of low Replace oil.
temperature
Wrong kind of oil used Replace oil.
5-66
Magnet strainer clogged Clean or replace.

Oil pump worn Replace.
Coil spring defective in main relief valve Replace.
Erratic movement of main relief valve spool Repair or replace.
Main pressure is too
low Air being sucked in Retighten or replace
packing.
Control linkage defective Repair or replace.
Clutch valve out of order Repair or replace.
Magnet strainer clogged Clean or replace.

Oil pump worn or otherwise defective Replace.
Coil spring defective in main relief valve Replace.
Erratic movement of main relief valve spool Repair or replace.
Clutch pressure is too packing.
low
Control linkage out of order Repair or replace.
Inching valve defective Repair or replace.
Seal ring broken in servo case Replace.
Clutch seal rings broken Replace.
Lack of engine power if the speed is slightly low in Tune up engine.

both forward and reverse drive
Stall speed out of
specification Stator and freewheel damaged if the speed is Replace stator assembly.
excessively low in both forward and reverse drive
Inching pedal linkage defective, or clutch slipping Repair or replace.
if the speed is too high
Travel speed select switch not in “AUTO” position Move switch to “AUTO”
position.
No automatic shifting Solenoid valve defective Replace.
(automatic 2-speed
transmission) Solenoid valve inlet orifice clogged Clean or replace.
Solenoid valve spool or spring defective Repair or replace.
ECU control box internally defective Check and replace.
5-67
Service Data
Unit: mm (in.)
Truck Model
GP40K, GP40KL, GP45K GP50K
DP40K, DP40KL, DP45K DP50K
Item
Gasoline engine: 2157
Stall speed (tolerance: ± 100 rpm) rpm
A Diesel engine: 1954
Main pressure
A 0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8]
(engine at 1600 ± 100 rpm) MPa (kgf/cm2) [psi]
Clutch pressure
A 0.98 to 1.23 (10.2 to 12.5) [142.2 to 177.8]
Torque converter inlet pressure

A 0.10 to 0.49 (1.0 to 5.0) [14.2 to 71.1]
1-speed T/M: 0.05 to 0.29 (0.5 to 3.0) [7.11 to 42.7]

Lubricating oil pressure
A Automatic
2-speed T/M: 0.05 to 0.29 (0.5 to 3.0) [7.11 to 42.7]
Travel time for 10 m (33 ft) starting acceleration (no load) A 5 seconds, maximum
0 0
A 70 − 0.046 (2.76 − 0.00181 )
Diameter of fitting surface in contact with
oil seal and bushing 1
B 69.90 (2.7520)
Pump boss
1
209983
5-68

Unit: mm (in.)
Truck Model
Item
− 0.007 − 0.00028
A 20 − 0.020 (0.78 − 0.00079 )
Diameter of shank in contact with
pilot bearing 1
B 19.95 (0.7854)
Pilot boss
209985
A 0.07 to 0.011 (0.0028 to 0.0043)

Side clearance 1
B 0.20 (0.0079)
A 0.17 to 0.26 (0.007 to 0.0102)

Top clearance 2
B 0.35 (0.0138)
A 0.2 to 0.4 (0.008 to 0.016)

Drive gear clearance in pump boss notch 3
B 1.0 (0.039)
Oil pump
2
3
209989
5-69

Unit: mm (in.)
Truck Model
Item
A 0.2 (0.008)
Face runout of flexible plate 1
(in free state)
B 0.5 (0.020)
Distance between end face of transmission

A 42 (1.65)
case and mating face of flexible plate 2
Flexible
plate
209978
5-70

Unit: mm (in.)
Truck Model
Item
2.3 ± 0.07
A –
(0.091 ± 0.0028)
Thickness of mating plate 1
B 2.1 (0.083) –
A 2.6 ± 0.1 (0.102 ± 0.004) –

Thickness of friction plate 2
B 2.2 (0.087) –
0.10 to 0.30
Backlash of friction plate and gear 3 A –
(0.0039 to 0.0118)
− 0.01 − 0.0004
A 4 − 0.03 (0.16 − 0.0012 ) –
Width of seal ring 4
B 3.5 (0.138) –
+ 0.2 + 0.008
A 4 + 0.1 (0.16 + 0.004 ) –
Width of piston seal ring groove 5
Clutches B 4.5 (0.177) –
Free length of clutch spring 6

63 (2.48)
Spring constant: A –
k=39.1 (3.992) [223.3]
k=N/mm (kgf/mm) [lbf/in.]
6 5
2
1
3
4 202900
Tightening torque for nut 1

A 353 to 392 (36 to 40) [260 to 289]
N·m (kgf·m) [lbf·ft]
1
Output shaft
(4th shaft)
200408
5-71

Unit: mm (in.)
Truck Model
GP40K, GP40KL, GP45K
DP40K, DP40KL, DP45K
Item
A 2.5 ± 0.05 (0.098 ± 0.0020)
Width of turbine shaft seal ring 1
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of piston seal ring groove in
turbine shaft 2
B 3.0 (0.118)
+ 0.025 + 0.00098
A 35 0 (1.38 0 )
Inside diameter of stator shaft in contact
with seal ring 3
B 35.2 (1.386)
A 2.5 ± 0.05 (0.098 ± 0.0020)

Width of clutch piston seal ring 4
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of clutch piston seal ring groove 5
B 3.0 (0.118)
Main shaft
(turbine shaft) A 2.5 ± 0.05 (0.098 ± 0.0020)
and servo Width of clutch shaft seal ring 6
case B 2.0 (0.079)
(1-speed
+ 0.2 + 0.008
transmission) A 2.5 + 0.1 (0.098 + 0.004 )
Width of clutch shaft seal ring groove 7
B 3.0 (0.118)
+ 0.025 + 0.00098
A 35 0 (1.38 0 )
Inside diameter of servo case in contact
with seal ring 8
B 35.2 (1.386)
6, 7 1, 2
8 4, 5 3
207591
Backlash of countergear and output gear A 0.14 to 0.27 (0.0055 to 0.0106)

Gear and
Backlash of other gears A 0.14 to 0.26 (0.0055 to 0.0102)
splines
Looseness of mating splines A 0.036 to 0.206 (0.00142 to 0.00811)
5-72

Unit: mm (in.)
Truck Model
GP50K
DP50K
Item
A 2.5 ± 0.05 (0.098 ± 0.0020)
Width of input shaft seal ring 1
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of input shaft seal ring groove 2
B 3.0 (0.118)
+ 0.025 + 0.00098
A 35 0 (1.38 0 )
Inside diameter of stator shaft in contact
with seal ring 3
B 35.2 (1.386)
A 2.5 ± 0.05 (0.098 ± 0.0020)

Width of input shaft seal ring 4
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of input shaft seal ring groove 5
B 3.0 (0.118)
+ 0.025 + 0.00098
A 35 0 (1.38 0 )
Inside diameter of servo case in contact
Input shaft
with seal ring 6
and servo B 35.2 (1.386)
case
(2-speed A 2.5 ± 0.05 (0.098 ± 0.0020)
transmission) Width of clutch piston seal ring 7
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
B 3.0 (0.118)
1,2
4,5 6 3
207597
5-73

Unit: mm (in.)
Truck Model
GP50K
DP50K
Item
A 2.5 ± 0.05 (0.098 ± 0.0020)
Width of countershaft seal ring 1
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
Width of countershaft piston seal ring groove 2
B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of pump body in contact A 35 0 (1.38 0 )
A 2.5 ± 0.05 (0.098 ± 0.0020)
Width of clutch piston seal ring 4
B 2.0 (0.079)
+ 0.2 + 0.008
A 2.5 + 0.1 (0.098 + 0.004 )
B 3.0 (0.118)
A 2.5 ± 0.05 (0.098 ± 0.0020)
Width of countershaft seal ring 6
B 2.0 (0.079)
Main shaft + 0.2 + 0.008
(turbine shaft) A 2.5 + 0.1 (0.098 + 0.004 )
and servo Width of countershaft seal ring groove 7
case B 3.0 (0.118)
+ 0.025 + 0.00098
Inside diameter of servo case in contact A 35 0 (1.38 0 )
8
6, 7 1, 2
4, 5
207602
Forward 1st speed gear and forward 2nd

A 0.14 to 0.23 (0.0055 to 0.0091)
speed gear
Backlash Forward gear and reverse gear A 0.14 to 0.24 (0.0055 to 0.0094)
Countergear and output gear A 0.14 to 0.25 (0.0055 to 0.0098)
Looseness of mating splines A 0.036 to 0.206 (0.00142 to 0.00811)
5-74

Unit: mm (in.)
Truck Model
Item
75 (2.95)
Free length of main relief valve inner spring 1 A
k = 2.11 (0.2154) [12.05]
Spring constant:
k = N/mm (kgf/mm) [lbf/in.]
B 72 (2.83)
Free length of main relief valve outer 50 (1.97)

A
spring 2 k = 0.838 (0.0855) [4.78]
Spring constant:
39 (1.54)
Free length of inching valve spring 3 A
k = 2.13 (0.217) [12.1]
Spring constant:
B 38 (1.50)
28 (1.10)
Free length of inching valve spring 4 A
k = 0.478 (0.0488) [2.73]
Spring constant:
B 26.5 (1.04)
Free length of torque converter inlet regulator 32 (1.26)

A
valve spring 5 k = 4.56 (0.465) [26.0]
Spring constant:
Control valve
Free length of accumulator valve outer 91 (3.58)
A
spring 6 k = 7.30 (0.7447) [41.7]
Spring constant:
Free length of accumulator valve inner 130 (5.12)

A
spring 7 k = 0.676 (0.0609) [3.40]
Spring constant:
32.5 (1.28)
Free length of directional spool spring 8 A
k = 8.616 (0.8786) [49.2]
Spring constant:
B 32 (1.26)
7
6
1
2
3
4
8 8
206614 5 203001
5-75

Unit: mm (in.)
Truck Model
Item
65 (2.56)
Free length of solenoid valve spring 1 A –
k = 1.79 (0.183) [55.9]
Spring constant:
B – 63 (2.48)
Solenoid valve
(automatic
2-speed
transmission)
1 202919
Inching pedal height 1

A 220 (8.7)
(from frame to top of pedal pad)
Clearance between inching pedal and brake

A 0.1 to 0.5 (0.004 to 0.020)
pedal connecting parts 2
Inching valve plunger stroke 3 A 6 to 9.5 (0.24 to 0.374)
Inching valve plunger stroke at which brake

A 16 (0.63)
starts to be applied 4
Rod and ball joint length 5 A 228 (8.98)
Inching pedal
control
200224 202915 202916
5-76

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POWERSHIFT TRANSMISSIONS

1-Speed Transmission (GP40K, GP40KL, GP45K, DP40K, DP40KL, DP45K)

Structures and Functions

Indicated in ( ) are numbers of gear teeth.

1 Flexible plate 6 Clutch shaft (1st shaft)

The M15 transmission for the models shown at the right

Shift positions Power path

Transmission reduction ratio

Torque Converter Assembly (GP40K, GP40KL, GP45K, DP40K, DP40KL, DP45K)

1 Turbine runner 9 Thrust washer

Torque Converter Drive Control

1 Forward-reverse shift lever 4 Solenoid valve (forward) 7 Clutch lever

1 Accumulator valve 3 Clutch valve plunger 5 Directional spool

(Valve top surface with M stamp)

Clutch (inching) valve

Removal and Installation Unit: mm (in.)

Removal Truck Model GP40K thru GP45K

(6) Separate the transmission from the engine. At this NOTE

NOTE (3) Sling the engine, transmission and differential as an

Suggestion for Removal

Inspection and Repair

A: Standard value B: Repair or service limit

(2) With the flexible plate installed in position on the

(GP40K, GP40KL, GP45K, DP40K,

Control Valve and Strainer

Pump Body Assembly

Suggestion for Disassembly

Removing pump body assembly Jack bolt

Unscrew all bolts securing the pump body assembly, and

Jack bolt 67284 - 15400

Countershaft (2nd shaft)

Suggestion for Disassembly

Countershaft (3rd shaft)

Suggestion for Disassembly

Removing ball bearing

Output Shaft (4th shaft)

Suggestion for Disassembly

1. Removing output shaft

2. Disassembling output shaft subassembly

Forward-reverse Clutch Shaft

Suggestion for Disassembly

Disassembling clutch drum

Piston tool A 92267 - 00300

Inspection and Repair

A: Standard value B: Repair or service limit

A: Standard value B: Repair or service limit

7. Clutch gears (forward and reverse)

A: Standard value B: Repair or service limit

Free length of clutch 63 (2.48)

8. Turbine shaft and clutch shaft

A: Standard value B: Repair or service limit

9. Clutch shaft, countershafts, and output shaft

11. Strainer assembly

Suggestions for Reassembly

Clutch Shaft Assembly A

Suggestions for Reassembly

Piston tool A 92267 - 00300

(3) Installing clutch plates

(b) Installing thrust washers

(4) After assembling the clutch, apply air pressure of

Output Shaft (4th shaft)

Suggestion for Reassembly

Countershaft (3rd shaft)